Disk mailer

ABSTRACT

The present invention provides for a mailer suitable for mailing a plurality of disks. This mailer is formed from a unitary sheet of foldable paperboard and is compatible with high-speed, automated mail handling equipment.

CROSS-REFERENCES TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

MICROFICHE APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of mailers and envelopes. More specifically, the present invention relates to a mailer for a plurality of disks (e.g., CDs or DVDs) that can be handled by the United States Postal Service (USPS) using high-speed, automated mail handling equipment.

2. Description of the Related Art

Digital Versatile Disks (DVDs) and Compact Disks (CDs) are optical media developed to record and play-back audio and audio/visual entertainment materials and to record and play-back data and other information. Many content providers use the DVD and CD formats to make their content available to consumers. These formats have the advantages of having a small form factor while still being able to store large amounts of data. However, the performance of these formats can be adversely affected by physical damage such as minor surface irregularities (such as scratches, smudges, abrasions, and the like) which sometimes cause data loss and/or inoperability. To protect against such physical damage, CDs and DVDs are usually packaged in rigid containers or boxes, commonly referred to as jewel cases (for CDs) and a slightly larger, rigid plastic container commonly used for DVDs. While these packaging systems are adequate and appropriate for retail sale, they are not optimized for shipping small quantities of disks. Frequently, content providers ship small quantities of CDs and/or DVDs in cardboard boxes. While these cardboard boxes provide protection for the included disks, they have the disadvantages of being bulky and expensive. Further, these cardboard boxes are heavy and not subject to processing on the USPS' automated equipment. Thus, postage costs for these types of shipments are significant.

Many content providers utilize the USPS to ship small quantities of disks to customers. For example, Netflix, Inc., has developed a single-disk packaging system in which a sending package and a return package are provided concurrently. While this system avoids jewel cases, cardboard boxes, and the like, and is designed to be compatible with the USPS high-speed, automated processing equipment, it is designed to accommodate only one disk at a time.

Accordingly, in this field there is a need for a packaging system that accommodates a plurality of disks and that is compatible with USPS high-speed, automated processing equipment. This packaging system should also be formed from low cost materials, be easily assembled, and be versatile in accommodating different labeling schemes.

BRIEF SUMMARY OF THE INVENTION

The present invention provides an inexpensive, non-bulky, mailing system for a plurality of CDs and/or DVDs that can be processed on USPS high-speed, automated mail handling equipment, and thus can achieve substantial savings in both packaging and postage costs.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a plan view, showing a preferred embodiment of the mailer of the present invention in an unfolded view.

FIG. 2 is a plan view, showing a preferred embodiment of the present invention in a partially folded view.

FIG. 3 is a plan view, showing a preferred embodiment of the present invention in a partially folded view including multiple disks.

FIG. 4 is a plan view showing a preferred embodiment of the present invention in a fully folded view, ready for mailing.

REFERENCE NUMERALS IN THE DRAWINGS 100 mailer 101 transverse fold line 101A transverse fold line 102 tab 103 slots 104 tab fold line 105 shoulder 106 upper panel 107 middle panel 108 lower panel 200 adhesive 300 disk 400 seal 401 addressee information 402 return address information

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is an unfolded view of the mailer 100 of the present invention. Mailer 100 is comprised of a single sheet of foldable paperboard. Preferably, mailer 100 is formed from paperboard with a basis weight in the range of 28-pounds to 36-pounds. Mailer 100 is divided into three, approximately equal sized panels (upper panel 106, middle panel 107, and lower panel 108) by transverse fold lines 101 and 101A. Each of panels 106, 107, and 108 has a front side (shown) and a back side (not shown). Tabs 102 extend from each side of lower panel 108. Each tab 102 includes a shoulder 105 at each longitudinal end of each tab 102 to facilitate folding of tab 102 along tab fold line 104. Each tab 102 includes a front side (shown) and a back side (not shown). Slots 103 are preferably diagonal cuts through the paperboard surface of lower area 108. Preferably, the length of slots 103 is slightly longer than the diameter of the media (typically CDs or DVDs) which slots 103 accommodate. In a preferred embodiment, slots 103 are 5 inches long, which is slightly longer than the diameter of a standard CD/DVD (4.7 inches).

FIG. 2 shows mailer 100 partially folded. Tabs 102 have been folded along tab fold lines 104 such that the front side of each tab 102 is brought into proximity to the front side of lower panel 108. Lower panel 108 is folded along transverse fold line 101A such that the front side of lower panel 108 is brought into proximity to the front side of middle panel 107 (no longer visible). The back sides of tabs 102 are secured to the front side of middle panel 107, preferably by adhesive 200. Folding lower panel 108 on top of middle panel 107 creates a pocket (not shown) for receiving materials. Securing the back sides of tabs 102 to the front side of middle panel 107 seals the sides of mailer 100 and allows for slight volumetric expansion of the created receiving pocket.

FIG. 3 shows mailer 100 with disks 300 inserted through slots 103. Because slots 103 are only slightly longer than the diameter of disk 300, the transverse motion of disk 300 in slot 103 is limited. Slots 103 are cut on a diagonal to facilitate easy loading of disks 300. However, other orientations of slots 103 can also be used (for example, slots 103 can be parallel). Preferably, the length and orientation of slots 103 are selected to prevent disks 300 from shifting more than ½ inch in any direction.

FIG. 4 shows mailer 100 in its final folded position. Upper panel 106 has been folded along transverse fold line 101 and the front side of upper panel 106 covers and is in contact with the back side of lower panel 108 (not shown). Seals 400 are tabs or wafer seals that prevent mailer 100 from unfolding or opening until seals 400 are removed or cut. Upper panel 106 can be printed with address information 401 and return address information 402. In its final folded form, mailer 100 preferably has a height of between 5.5 and 6 inches, a length of between 7.25 and 9.75 inches, a thickness of between 0.009 and 0.25 inches, and a weight of not more than 3 ounces.

Mailer 100 can be manufactured from a single piece of paperboard and, in a preferred embodiment, die cut into the blank shown in FIG. 1. Slots 103 are also die cut during this initial step. Next, mailer 100 is machine folded with tabs 102 being folded and glued to middle area 107 as described above. Mailer 100 is then ready for insertion of disks 300. Once disks 300 are inserted, the final fold may be made by folding upper area 106 over lower area 108. At this point, seals 400 are applied to ensure the integrity of mailer 100 for processing through the USPS' high-speed, automated mail handling equipment.

In an alternative embodiment, after the blank for mailer 100 is cut, and before any folding occurs, mailer 100 is run through a printing machine where address information 400 and return address information 401 are printed on the back side of upper panel 106. Further, advertising, promotional, or other information may be printed on any available side of panels 106, 107, and 108 during this printing process.

The preceding description contains significant detail regarding the novel aspects of the present invention. It should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Thus, the scope of the invention should be fixed by the following claims, rather than by the examples given. 

1. A mailer for media items comprising: a. a unitary, foldable paperboard blank; b. a first transverse fold line on said blank, said first fold line forming a line of delineation between an upper panel and a middle panel; c. a second transverse fold line on said blank, said second fold line forming a line of delineation between said middle panel and a lower panel; d. a foldable tab attached to a left side of said lower panel; e. a foldable tab attached to a right side of said lower panel; f. a plurality of slots cut into said lower panel, each of said slots sized to accommodate insertion of said media item; g. adhesive for securing each of said foldable tabs to said middle panel; h. at least one seal; whereby, said mailer is created by folding said foldable tabs over said lower panel and folding said lower panel, along said second transverse fold line, over said middle panel and securing said foldable tabs to said middle panel to create a receiving space for said media items; and by folding said upper panel, along said first transverse fold line, over said lower panel, and sealing a bottom edge of said mailer with said at least one seal.
 2. The mailer as recited in claim 1, wherein said paperboard has a basis weight of at least 28 pounds.
 3. The mailer as recited in claim 1, wherein said paperboard has a basis weight of at least 32 pounds.
 4. The mailer as recited in claim 1, wherein said mailer has a height of between 5.5 inches and 6 inches.
 5. The mailer as recited in claim 4, wherein said mailer has a length of between 7.25 inches and 9.75 inches.
 6. The mailer as recited in claim 1 wherein said mailer has a thickness of 0.25 inches or less.
 7. The mailer as recited in claim 1, wherein said upper panel, said middle panel, and said lower panel are substantially the same in size.
 8. The mailer as recited in claim 1, wherein said upper panel, said middle panel, and said lower panel are adapted to receive and display printed information. 